Hypertherm T100M Instructions De Service page 4

All torches except T100M-2
Cap sensor
switch
Cap sensor
switch wires
Torch body
Plunger
Power wire
terminal
Remove the torch body
1. Disconnect the blue and orange cap sensor switch wires.
2. Disconnect the plunger:
• For all torches except the T100M-2, remove the retaining ring from the plunger using needle nose pliers
and discard the ring. Disconnect the power wire terminal from the plunger.
• For the T100M-2, use a #1 Phillips screwdriver and a 1/4" wrench to remove and discard the screws that
secure the power wire to the plunger.
3. Carefully cut off the clear heat shrink tubing on the gas tube. Remove the torch body from the lead using 7/16"
and 1/2", or adjustable, wrenches.
4. Remove the old positioning sleeve.
Install the new positioning sleeve
1. Slide the new positioning sleeve onto the torch lead.
2. Slide the heat shrink tubing on to the gas tube of the torch body.
3. Attach the torch body to the new torch lead using 7/16" and 1/2", or adjustable, wrenches.
4. Slide the heat shrink tubing over the nut as far as possible and heat shrink it in place.
5. Attach the orange and blue cap sensor switch wires to the cap sensor switch.
6. Attach the power wire terminal to the plunger:
• For all torches except the T100M-2, secure the terminal by using needle nose pliers to crimp the new
retaining ring onto the top of the plunger.
• For the T100M-2, use a #1 Phillips screwdriver and a 1/4" wrench to fasten the power wire to the plunger
using a torque value of 8 in-lbs (9.2 kg-cm) for the two screws.
Field Service Bulletin
Retaining ring
POSITIONING SLEEVE REPLACEMENT
T100M-2
Cap sensor
switch
Torch body
Plunger
Screws
Locknuts
3
5